Laminated pocket zipper with zipper-lip, method of making same and storage cab thereof

ABSTRACT

Disclosed is an improved laminated pocket zipper with a zipper-lip formed on a garment, including: an upper fabric, having at least one “[” or   shaped slit of a first length for dividing the upper fabric into a base section and a flap section, the flap section having a free edge and an anchor portion; a water-tight zipper of a second length, provided underneath the upper fabric such that engaged teeth of the zipper adapt to locate underneath the flap section; and a reinforcing member of the first length, binding the free edge of the flap section by straddling over the free edge, whereby a zipper-lip is formed over the zipper to provide improved water-resistant capability and better appearance; further disclosed is a method of making such a laminated pocket zipper with a zipper-lip.

CROSS-REFERENCES TO RELATED APPLICATIONS

This is a continuation-in-part of patent application Ser. No. 10/891,611, filed on 15 Jul. 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

TECHNICAL FIELD

The invention relates to an improved laminated pocket zipper, particularly to an improved laminated pocket zipper with a zipper-lip and a method of making the same.

DESCRIPTION OF THE RELATED ART

Ever since the laminated workmanship was widely used in outdoor clothing manufacturing, the laminated water-resistant zipper has become a key feature of the suppliers of advanced gears.

One prior laminated pocket zipper developed by Arc'teryx is shown in FIGS. 1, 2 and 2A. In such a prior laminated pocket zipper 1, a water-tight zipper 5 is affixed to an underside of an outer-shell 2 of the garment. An elongated opening 4 having a width of approximately 1.2 cm and a length that accommodates the zipper 1 is cut through the out-shell 2. A glue film 6 consisting of a thermally meltable compound then serves as a bridge for laminated the zipper 1 to the out-shell 2. As best illustrated in FIG. 2A, 60% of the zipper tapes and the entire teeth are constantly exposed to the outside. Since it is rare that the colour of the garment is identical to the colour of the zipper tapes and teeth of the zipper, zippers of black or darker colours are usually implemented to improve the overall appearance of the garment.

Though such a design eliminates the bulky flap and reduces the garment's overall weight, it involves the drawback of exposing the zipper tapes to the outside, rendering difficulty in matching the colours of garment with those of the zipper; long exposure of the zipper of the outside would also result in inevitable water infiltration into the garment through gaps of the closed teeth. In addition, it is not unusual to observe de-lamination of the out-shell fabric from the zipper tapes when the garment ages, thereby reducing the durability of the garment.

To overcome the drawbacks of such a design, an improved version is developed by Nike, as shown in FIGS. 3, 4 and 4A. As shown, the garment is made of a multi-layer fabric 11 and a zipper 15 that is affixed to the garment by means of a portion (shown in hatch lines) of glue films 16 consisting of a thermally meltable compound, to form flaps and to reduce the width of elongated opening 14 to approximately 0.20 cm.

Though such an improved version reduces the extent that the zipper tapes are expose to the outside and improves the colour matching problem, the narrow opening that still exposes parts of the zipper tapes cannot eliminates water leakage completely, and would still result in water infiltration into the garment through gaps of the closed teeth. In addition, the narrow width of the opening requires a zipper with smaller teeth and a smaller slider, such as from a commonly adopted #5 to #3, which is not suitable and realistic for the outdoor clothing.

SUMMARY OF INVENTION

To overcome the drawbacks of the prior art, it is thus an object of the present invention is to provide an improved laminated pocket zipper with a zipper-lip, which makes the laminated pocket look neat and elegant.

It is another object of the present invention to provide an improved laminated pocket zipper with a zipper-lip with better durability by preventing fraying and de-lamination of the shell fabric from the zipper tape when the garment ages.

It is yet another object of the present invention to provide an improved laminated pocket zipper with a zipper-lip with enhanced water-resistant effects.

It is another objective of the present invention to provide a method for making such an improved laminated pocket zipper with a zipper-lip.

To achieve these objects, the improved laminated pocket zipper with a zipper-lip in accordance with the present invention comprises: an upper fabric, having at least one “[” or

shaped slit of a first length for dividing the upper fabric into a base section and a flap section, the flap section having a free edge and an anchor portion; a water-tight zipper of a second length, provided underneath the upper fabric such that engaged teeth of the zipper adapt to locate underneath the flap section; and a reinforcing member of the first length, binding the free edge of the flap section by straddling over the free edge.

According to another aspect of the present invention, the improved laminated pocket zipper with a zipper-lip may further comprise a first thermally meltable compound provided between the flap section and the first zipper tape for affixing the first zipper tape to the anchor portion, and a second thermally meltable compound provided between the base section and the second zipper tape for affixing the second zipper tape to the base section.

According to yet another aspect of the present invention, the improved laminated pocket zipper with a zipper-lip can be further provided with a small cab on the top of the slit which can store the zipper's slider when it is zipped. By doing this way, the zipper-Lip and the slider's cab can offer a zipper pocket with quasi-waterproof function when a waterproof fabric is used as shell and a water-tight zipper is used. Alternatively, when a non-coated fabric is used as the shell, the zipper-lip and the cab thereof can offer a unique outlook in the outwear clothing.

Accordingly, the present invention further discloses a method of making a laminated pocket zipper with a zipper-lip, comprising the steps of: (a) providing an upper fabric; (b) placing a thermally meltable compound underneath the upper fabric; (c) cutting a “[” or

shaped slit of a first length through the upper fabric and the thermally meltable compound to divide the upper fabric and the thermally meltable compound each into a base section and a flap section, the flap section having a free edge and an anchor portion; (d) placing a first zipper tape of a second length underneath the anchor portion of the flap section of the upper fabric and substantially parallel to the “[” or

shaped slit; (e) placing a second zipper tape of the second length underneath the base section of the upper fabric and substantially parallel to the “[” or

shaped slit, where the second zipper tape extends beyond the “[” or

shaped slit to be engageable with the first zipper tape; (f) straddling a reinforcing member of the first length over the free edges of the flap section and the thermally meltable compound; and (g) heat-pressing the upper fabric along the “[” or

shaped slit with a thermal pressing machine.

These and other modifications and advantages will become even more apparent from the following detained description of a preferred embodiment of the invention and from the drawings in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of a garment having a prior laminated pocket zipper;

FIG. 2 is an enlarged view of the prior laminated pocket zipper of FIG. 1;

FIG. 2A is a cross-sectional view taken along lines 2A-2A of FIG. 2;

FIG. 3 is a schematic drawing of a garment having a prior laminated pocket zipper;

FIG. 4 is an enlarged view of the prior laminated pocket zipper of FIG. 3;

FIG. 4A is a cross-sectional view taken along lines 4A-4A of FIG. 4;

FIG. 5 is a schematic drawing of a garment having a laminated pocket zipper with a zipper-zip according to the present invention;

FIG. 6 is an enlarged view of the laminated pocket zipper with a zipper-zip of FIG. 6;

FIG. 6A is a cross-sectional view taken along lines 6A-6A of FIG. 6;

FIG. 7 is a schematic drawing of a garment having a laminated pocket zipper with a zipper-zip and a storage cab according to the present invention;

FIG. 8 is an enlarged view of the laminated pocket zipper with a zipper-zip and a cab of FIG. 7; and

FIG. 8A is a cross-sectional view taken along lines 8A-8A of FIG. 8.

DETAILED DESCRIPTION OF THE INVENTION (PREFERRED EMBODIMENTS)

With reference to FIG. 5, an improved laminated pocket zipper 100 with a zipper-lip in accordance with the present invention is formed on a garment 50.

As shown in FIGS. 5 and 6, the improved laminated pocket zipper 100 includes an upper fabric 110. The upper fabric 110 is a part of an outer-shell of the garment 50 or another piece of fabric to be sewn to the outer-shell of the garment 50.

FIG. 6A is a cross-sectional view taken along lines A-A of FIG. 6 and best illustrates the structure of the improved laminated pocket zipper 100 of the present invention. As shown in FIGS. 6 and 6A, the upper fabric 110 is formed with at least one “[” shaped slit 140 stretched for a first length for dividing the upper fabric 110 into a base section 112 and a flap section 114. The flap section 114 includes a “[” shaped free edge 116 and an anchor portion 118.

A water-tight zipper 150 of a second length is provided underneath the upper fabric 110. To improve the water-resistant capability of the laminated pocket zipper, according to the present invention, teeth of the zipper 150 after engagement adapt to locate underneath the flap section 114. To achieve such an object, the water-tight zipper 150 includes: a first zipper tape 152, a second zipper tape 154 and a slider (not shown in figure).

The first zipper tape 152 includes a tooth side 152A and a fixing side 152B. The first zipper tape 152 is provided underneath the flap section 114 of the upper fabric 110 such that the fixing side 152B of the first zipper tape 152 is affixed to the anchor portion 118 of the flap section 114 and the tooth side 152A of the first zipper tape 152 lies underneath the flap section 114.

The second zipper tape 154 includes a tooth side 154A and a fixing side 154B. The second zipper tape 152 is provided underneath the base section 112, where the fixing side 154B of the second zipper tape 154 is affixed to the base section 112 of the upper fabric 110 and the tooth side 154A of the second zipper tape 154 extends beyond the “[” shaped slit 140 to engage with the tooth side 152A of the first zipper tape 152 underneath the flap section 114 by the slider disposed between the first and the second zipper tapes 152, 154.

The length of the “[” shaped slit 140 adapts to accommodate the length of the zipper 150, possibly ranging from 14 cm to 35 cm according to the garment design.

To affix the first and second zipper tapes 152, 154 of the zipper 150 to the upper fabric 110, a first thermally meltable compound 162 is provided between the flap section 114 and the first zipper tape 152 for affixing the first zipper tape 152 to the anchor portion 118 of the flap section 114. A second thermally meltable compound 164 is further provided between the base section 112 and the second zipper tape 154 for affixing the second zipper tape 154 to the base section 112.

The thermally meltable compound 162, 164 may each be a thermally meltable polyurethane resin in form of a glue film that would melt upon being heated by a thermal welding machine to result in adhesion effects. The glue films may each have a width of approximately 3 cm if a #5 YKK water-tight zipper is used.

If a #5 YKK water-tight zipper is used, the fixing sides 152B, 154B of the first and second zipper tapes 152, 154 may be affixed to the anchor portion 118 of the flap section 114 and the base section 112, respectively, for approximately 0.80 cm on each side (shown by hatch lines), leaving a centre region of the zipper 150 of approximately 1.40 cm free from affixation, such that the flap portion 114 not affixed to the zipper 150 would serve as a zipper-lip, as shown in FIG. 6, to cover the teeth sides 152A, 154B after engagement. Accordingly, there is no need to find a zipper that matches the fabric upper and the garment would be featured with a better appearance that does not appear as aggressive as a garment having an exposed zipper.

To prevent fraying and de-lamination of the upper fabric 110 from the first zipper tape 152 when the garment 50 ages, the improved laminated pocket zipper 100 of the present invention may further be provided with a reinforcing member 160 of the first length for binding the free edge 116 of the flap section 114 by straddling over the free edge 116 and the first thermally meltable compound 162.

Alternatively, as shown in FIGS. 7 and 8, the slit 140′ can be cute to a “[” shape, which can has a width of 0.7 cm (shown by the hatch line). When the length of the first and second zipper tapes 152′, 154′ is larger than that of the slit 140′, the upper end of the first and second zipper tapes 152′, 154′ is underneath the upper fabric 110′ beyond the upper end of the slit 140′. The first thermally meltable compound 162′ and the second thermally meltable compound 164′ can affix the fixing side 152B′ of the first zipper tape 152′ and the fixing side 154B′ of the second zipper tape 154′ beyond the length of the slit 140′. An enclosed hollow space 172 can be formed between the upper fabric 110′, the first zipper tape 152′ and the second zipper tape 154′ by a mould. The enclosed hollow space 172, which serves as a cab 170 and can be of 2 cm wide, can be used to accommodate a slider 156. Additionally, a second layer of fabric 171 can be affixed underneath the upper fabric 110′ in the hollow space 172 to reinforce the cab 170.

According to this embodiment, the reinforcing member 160 is made of polyurethane (PU). It may also be made of PTFE, PVC, or rubber coated/laminated fabrics. Accordingly, the reinforcing member 160 has a width of approximately 1 cm that binds the free edge 116 of the flap section 114 for approximately 0.50 cm on each of the opposing faces of the free edge 116 and, such that the reinforcing member 160 also stiffens the zipper-lip to keep its shape all the time.

According to the present invention, the upper fabric, the first and second zipper tapes may be made of woven or knit man-made fabric (such as nylon, polyester, TC, CN), or impregnated fabrics (such as PU, PTFE, PVC, or rubber coated/laminated fabrics). However, it should be noted that while applying the present invention to other types of garments, the fabrics for the garment's shell can also be non-impregnated, especially highly breathable fabrics, which makes the garment fashionable with a neat outer appearance. Accordingly, the present invention may be applied to a wide variety of fashions, but not limited to outdoor clothing.

A preferred embodiment for the method of making the laminated pocket zipper 100 with a zipper-lip in accordance with the present invention is described as follows:

(a) providing an upper fabric;

(b) placing a thermally meltable compound underneath the upper fabric;

(c) cutting a “[” or

shaped slit of a first length through the upper fabric and the thermally meltable compound to divide the upper fabric and the thermally meltable compound each into a base section and a flap section, the flap section having a free edge and an anchor portion;

(d) placing a first zipper tape of a second length underneath the anchor portion of the flap section of the upper fabric and substantially parallel to the “[” or

shaped slit;

(e) placing a second zipper tape of the second length underneath the base section of the upper fabric and substantially parallel to the “[” or

shaped slit in such a manner that the second zipper tape extends beyond the “[” or

shaped slit to be engageable with the first zipper tape;

(f) straddling a reinforcing member of the first length over the free edges of the flap section and the thermally meltable compound; and

(g) heat-pressing the upper fabric along the “[” or

shaped slit with a thermal pressing machine.

Additionally, when the second length of the first zipper tape and the second zipper tape is larger than the first length of the slit, the upper end of the first zipper tape and the second zipper tape are placed underneath the upper fabric beyond the upper end of the slit. The thermally meltable compound can further affix the first zipper tape and the second zipper tape beyond the first length of the slit which forms an enclosed hollow space (a cab) by a mould between the upper fabric, the first zipper tape and the second zipper tape. A second layer of fabric can be further affixed underneath the upper fabric in the hollow space to reinforce the cab.

Because the improved laminated pocket zipper in accordance with the present invention provides a zipper-lip that covers the closed teeth of the zipper after engagement, the zipper-lip makes the laminated pocket look neat and elegant and enhances water-resistant effects by eliminating exposure of the zipper from the outside without adopting a bulky design. While the preferred embodiments have only focued on the slit formed on one side of the garment, persons skilled in the art can easily duplicate a zipper-lip on the other side of the garment by flipping the slit which may be a “]” shape for example.

In addition, the reinforcing member according to the present invention features the zipper-lip with better durability and prevents fraying and de-lamination of the shell fabric from the zipper tape when the garment ages.

The structure of the present invention is not limited to the above embodiments. Although the invention has been described with reference to the preferred embodiments, it will be obvious to persons skilled in the art that various changes and modifications may be made without departing from the scope of the invention as recited in the claims. 

1. An improved laminated pocket zipper with a zipper-lip formed on a garment, comprising: an upper fabric, having at least one slit of a first length for dividing the upper fabric into a base section and a flap section, the flap section having a free edge and an anchor portion; a water-tight zipper of a second length, provided underneath the upper fabric such that engaged teeth of the zipper adapt to locate underneath the flap section; and a reinforcing member of the first length, binding the free edge of the flap section by straddling over the free edge.
 2. The improved laminated pocket zipper with a zipper-lip of claim 1, wherein the water-tight zipper includes: a first zipper tape having a tooth side and a fixing side, the first zipper tape being provided underneath the flap section of the upper fabric such that the fixing side of the first zipper tape is affixed to the anchor portion and the tooth side of the first zipper tape lies underneath the flap section; a second zipper tape having a tooth side and a fixing side, the second zipper tape being provided underneath the base section, where the fixing side of the second zipper tape is affixed to the base section and the tooth side of the second zipper tape extends beyond the slit to engage with the tooth side of the first zipper tape underneath the flap section; and a slider disposed between the first and the second zipper tapes to engage the tooth sides of the first and the second zipper tapes.
 3. The improved laminated pocket zipper with a zipper-lip of claim 2, further comprising a first thermally meltable compound provided between the flap section and the first zipper tape for affixing the first zipper tape to the anchor portion, and a second thermally meltable compound provided between the base section and the second zipper tape for affixing the second zipper tape to the base section.
 4. The improved laminated pocket zipper with a zipper-lip of claim 1, wherein the slit is of a “[” shape.
 5. The improved laminated pocket zipper with a zipper-lip of claim 3, wherein the slit is of a

shape.
 6. The improved laminated pocket zipper with a zipper-lip of claim 5, wherein the second length of the water-tight zipper is larger than the first length of the slit such that the upper end of the water-tight zipper is underneath the upper fabric beyond the upper end of the slit, and the first thermally meltable compound and the second thermally meltable compound further affix the fixing side of the first zipper tape and the fixing side of the second zipper tape beyond the first length of the slit forming an enclosed hollow space between the upper fabric, the first zipper tape and the second zipper tape to accommodate the slider.
 7. The improved laminated pocket zipper with a zipper-lip of claim 6, wherein a second layer of fabric is affixed underneath the upper fabric in the hollow space.
 8. The improved laminated pocket zipper with a zipper-lip of claim 3, wherein the first thermally meltable compound is a thermally meltable polyurethane resin in form of a glue film.
 9. The improved laminated pocket zipper with a zipper-lip of claim 3, wherein the second thermally meltable compound is a thermally meltable polyurethane resin in form of a glue film.
 10. The improved laminated pocket zipper with a zipper-lip of claim 1, wherein the reinforcing member is made of polyurethane (PU).
 11. The improved laminated pocket zipper with a zipper-lip of claim 2, wherein the upper fabric, the first and second zipper tapes are made of impregnated woven fabric.
 12. The improved laminated pocket zipper with a zipper-lip of claim 2, wherein the upper fabric, the first and second zipper tapes are made of non-impregnated woven fabric.
 13. The improved laminated pocket zipper with a zipper-lip of claim 2, wherein the upper fabric, the first and second zipper tapes are made of knit man-made fabric.
 14. The improved laminated pocket zipper with a zipper-lip of claim 1, wherein the upper fabric is a shell of the garment.
 15. A method of making a laminated pocket zipper with a zipper-lip, comprising the steps of: a. providing an upper fabric; b. placing a thermally meltable compound underneath the upper fabric; c. cutting a slit of a first length through the upper fabric and the thermally meltable compound to divide the upper fabric and the thermally meltable compound each into a base section and a flap section, the flap section having a free edge and an anchor portion; d. placing a first zipper tape of a second length underneath the anchor portion of the flap section of the upper fabric and substantially parallel to the slit; e. placing a second zipper tape of the second length underneath the base section of the upper fabric and substantially parallel to the slit in such a manner that the second zipper tape extends beyond the slit to be engageable with the first zipper tape; f. straddling a reinforcing member of the first length over the free edges of the flap section and the thermally meltable compound; and g. heat-pressing the upper fabric along the slit with a thermal pressing machine.
 16. The method of claim 15, wherein the slit is of a “[” shape.
 17. The method of claim 15, wherein the slit is of a

shape.
 18. The method of claim 17, wherein the second length of the first zipper tape and the second zipper tape is larger than the first length of the slit such that the upper end of the first zipper tape and the second zipper tape are placed underneath the upper fabric beyond the upper end of the slit, and the thermally meltable compound further affixes the first zipper tape and the second zipper tape beyond the first length of the slit forming an enclosed hollow space by a mould between the upper fabric, the first zipper tape and the second zipper tape.
 19. The method of claim 17, wherein a second layer of fabric is affixed underneath the upper fabric in the hollow space.
 20. The method of claim 15, wherein the thermally meltable compound is a thermally meltable polyurethane resin in form of a glue film.
 21. The method of claim 15, wherein the upper fabric, the first and second zipper tapes are made of impregnated woven fabric.
 22. The method of claim 15, wherein the upper fabric, the first and second zipper tapes are made of non-impregnated woven fabric.
 23. The method of claim 15, wherein the upper fabric, the first and second zipper tapes are made of knit man-made fabric.
 24. The method of claim 15, wherein the reinforcing member is made of polyurethane (PU).
 25. The method of claim 15, wherein the upper fabric is a shell of a garment. 